Development and Evaluation of Hybrid Sol-Gel Coatings for Enhanced Corrosion Resistance on Mild Steel

Authors : Mohammed Jaber Abed Al-owaidi1, İsmail Hakkı Kara, Fatih Hayat

Pages : 287-295

Doi:10.52795/mateca.1736960

View : 46 | Download : 109

Publication Date : 2025-12-30

Article Type : Research Paper

Abstract :This article describes the design, synthesis, and characterization of sol–gel hybrid coatings to improve corrosion protection for low-carbon steel. We intensively studied System A (TEOS/MPTS) and System B (TEOS/MPTS/PhTMS). The process included dip-coating, then temperature curing, and we applied techniques like SEM, XRD, FTIR, contact angle measurements, and potentiodynamic Tafel polarization tests to characterize the results. The SEM and FTIR analyses confirmed that we properly developed dense, cross-linked siloxane networks, and XRD patterns suggested mainly amorphous structures. The contact angle measurements demonstrated a significant improvement in hydrophobicity, with System A exhibiting a contact angle value of 89.8° for the TE3 sample. Electrochemical measurements indicated significant corrosion current density decreases for System A (i_corr = 8.13 µA/cm², 91% improvement in comparison to bare steel), while System B showed a relatively less significant enhancement. Contrary to expectations, films cast from freshly synthesized sols outperformed those from aged sols, underlining the significance of sol aging in film homogeneity and barrier performance. Overall, the hybrid sol–gel coatings, especially TEOS/MPTS formulations, exhibit effective physical and chemical protective properties against corrosion and enhanced hydrophobicity and barrier properties. The precursor mixture, sol aging, and deposition parameters must be optimized to ensure optimal performance and uniformity. These findings portend a promising future for these green, scalable, and long-lasting protective coatings in industrial applications.
Keywords : Sol-jel kaplama, Yumuşak çelik, Korozyon direnci, MPTS, PhTMS.

ORIGINAL ARTICLE URL